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Old 02-09-2010, 03:29 PM
Big Maico 393's Avatar
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Default 490 Maico Build

     

Most of you know that Char, Sab,Cycle Rayn & I all race the local Evo-Vintage series here in Houston.

A few weeks a go one of the other guy's (Rhett) that races with us comes up to me & introduces me to a new guy ( Greg )that was looking into getting a Evo bike to race & Greg said that a friend of his has a 490 Maico & that he could get it from him, he wanted to know if that would be a good bike to race & have fun with I told him look around at what is parked where we were standing (3 Maico's) Greg asked Rhett who he sould have rebuild this Maico when he got it.

All I saw was 5 guy's pointing at me & saying let Howard do it! well after a few weeks Greg got the 490 & it had been sitting in a garage since 1997 & it's needs a lot of work to get it ready for the 2010 season.

What follows is a little of what I'm doing as I rebuild the 490 into a full on ready to rock racer.

How I got it from Greg







So far I've got the motor apart & found that the clutch cover is broken where the shift shaft go in the case, it's being repaired so no before picture.

I also found problems with the clutch basket needing to be re-riveted & the center clutch gude was stuck to the clutch basket from being run with too little oil, I've already fixed that & did the clutch mod. It's a little hard to see in the following pictures, but if you look at the pic that says Mod clutch guide you can see some of the tool marks that I removed. too the pic before I finnshed the mod.




So far I've go the seat rebuilt & modified

Powdered coated frame

Powder coated swingarm & forks


The powdered coating was done by Steve @ precisionpowder @sbcglobal.net one of our Evo-vintage racers at a great price!

More to come later, I'm off to barrow a soda blaster to clean 30 years of crud off the engine & order a piston for a rebore that needs to be done.

Last edited by Big Maico 393; 09-15-2010 at 07:05 AM.
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Old 02-09-2010, 03:49 PM
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Looks good Howard..........
You did good work on my Maico also.
Mike
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Old 02-09-2010, 05:12 PM
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It's about time you showed us how to build a Maico H. Looking forward to the next installment....
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Old 02-09-2010, 05:32 PM
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I'm sure it will be better than new by the time you are done with it!
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Old 02-09-2010, 07:17 PM
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you are living the dream
Owning and racing a Maico 490 is just about every motocrossers dream (over the age of 45 )
My Brother in Law put a YZ490 rod in his.Says the big bearing is larger than the Maico
Do you have a PVL ignition for it?
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Old 02-09-2010, 08:11 PM
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man that looks like so much fun. I just wish i had the time and knowledge for something like that.
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Old 02-09-2010, 09:31 PM
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Quote:
Originally Posted by MaxPower View Post
you are living the dream
Owning and racing a Maico 490 is just about every motocrossers dream (over the age of 45 )
My Brother in Law put a YZ490 rod in his.Says the big bearing is larger than the Maico
Do you have a PVL ignition for it?

Not my bike, so no PVL & I have a good Motoplat in mine!

I heard of running the yz rod & piston, but you have to run a 5mm base plate.

If you run Castor type premix @32:1 & watch teh jetting you don't have to worry about the rod bearing. trust me on this one, been there done that!
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Old 02-10-2010, 11:18 AM
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Heck of a project Big. Looks like it's progressing nicely. Does the
powder match the plastic OK? Do you do your own suspension
work or send it out? That seat mod looks like a real nice upgrade.

By the way, is your race number "69" a nod to Nicky Hayden, a
tribute to "Bill and Ted's Excellent Adventure", or does it have
some other significance?

dogger
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Old 02-10-2010, 01:31 PM
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Way to go H. Its about time you did something productive, besides...nevermind. LOL seriously, this will be cool to follow!
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Old 02-10-2010, 02:21 PM
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Looking great so far H. keep us up to date on your progress. Oh yeah some more pictures too.

BTW it looks like I am out for this season with my ACL repair, PT says pretty much going to take 12 months to be able to race again. I was looking so much to racing my Husky this year..
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Old 02-10-2010, 03:02 PM
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Quote:
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BTW it looks like I am out for this season with my ACL repair........I was looking so much to racing my Husky this year..
Sorry to hear that. Heal up good for us. Remember now, I'm certified for Hooska's. Where do I send the resume?.?.?.
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Old 02-10-2010, 06:23 PM
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Quote:
Originally Posted by dogger315 View Post
Heck of a project Big. Looks like it's progressing nicely. Does the
powder match the plastic OK? Do you do your own suspension
work or send it out? That seat mod looks like a real nice upgrade.

By the way, is your race number "69" a nod to Nicky Hayden, a
tribute to "Bill and Ted's Excellent Adventure", or does it have
some other significance?

dogger
Dogger,

the powdercoat sort of matches the plastic, as Maico did have 2 different shades of RED.one darker then the other, on this set of plastic the powder is real close & when the graphics are put on they will match the powder.

Normally I can rebuild a set of shocks, but this is a set of Works Performance that need to have the valving checked, so i sent them off to works for a rebuild & possible re-valve.

The front damper rods have already been modified & I'll get them setup to work.

The seat mod lets you get up on the tank like a modern bike & you can really stick the front end.

My race number is the number that came on the 82 maico I bought back in 2000 to start reacting Evo-Vintage, I was going to run my old race number for back in the day, but someone else in the Evo class was running # 64, so I went with what was on the bike.

Going to barrow a soda blaster & clean the case's, triple clamps & a few other thing's to get the years of crud off from sitting for 20 years!

More pictures to come, just sorry that I don't have a good digital camera, mine just doesn't do the powdercoat job justice!

Last edited by Big Maico 393; 02-10-2010 at 08:06 PM.
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Old 02-10-2010, 07:18 PM
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Quote:
Originally Posted by Big Maico 393 View Post
Dogger,



The seat mod let you get up on the tank like a modern bike & you can really stick the front end.
!

And it protects the boys.
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Old 02-11-2010, 01:02 AM
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There should be a pile -o- Maico 490s racing this season....
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Old 02-11-2010, 06:31 AM
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Quote:
Originally Posted by cycleryan View Post
There should be a pile -o- Maico 490s racing this season....

Yup! Looks like Evo II will have a few

Alan Green
Mike Ryan
Greg Conn
Myself
Kyle on His 400 Maico
Tom Day might be back on his 440 also
Maybe the guy from Dallas & his 490?
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Old 02-11-2010, 10:58 AM
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Quote:
Originally Posted by Silver_Fox View Post
And it protects the boys.
;lmao
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Old 02-11-2010, 03:46 PM
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Loving this thread. Can't wait to see the finished product.
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Old 02-12-2010, 11:39 AM
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A few more pictures of what I started with.

The top triple clamp/steering stem nut was damaged & I couldn't get it removed, I tried heat & PB Blaster,but who ever tried to remove it before me did to much damage. I had to take it to my machinist/fabricator & he just welded a aluminum bar on it & hit it with a BIG hammer.



The previous owner did some damage to the pipe by putting a hose clamp around the pipe & the frame, this is a BIG mistake! as the pipes on the 490 vibrate a ton & by doing this you cause the pipe to crack!

The fix is to get Teflon chemical pump packing & put it in the exhaust manifold & let the pipe vibrate. had the fabricator fix the pipe & the broken exhaust manifold.



If you look at the pipe mounting bolt & spring, you can see where it broke the mounting lug on the exhaust manifold, just between the frame & the cable.

Going to barrow a Soda blaster tomorrow & clean up the pipe,triple clamps & the cases.



BTW: see the 17mm black nut's on the bottom of the case? those are not oil drain plugs! DO NOT REMOVE unless your are removing the whole transmission from the case's one holds the shifting plate in & the other is for the shift detent, Maico's don't use a shift drum like most bikes.




I will try to post the "After " pictures late tomorrow, I should have a bunch of parts coming in early next week, Including a new piston. hopefully the shock will be back by the end of the next week.

Last edited by Big Maico 393; 02-12-2010 at 02:18 PM.
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Old 02-12-2010, 12:54 PM
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Seen all of this and worse. I'm constantly amazed and saddened
at what these magnificant machines are subjected to by some of
our more "creative" brethren.

Good call on the soda blaster. You should be able to make those cases
look brand new. That head pipe looks pretty rough, you may have to hit
it with a palm sander starting with #60 and working your way up to #240
before painting. More than once, I have had to cut the entire head pipe
area off and fab up new pieces because of rust through or deep pitting.
Hopefully yours is only superficial.

Going to be a stout racer when you're done.

dogger
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Old 02-12-2010, 02:22 PM
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Dogger,


I think that I'm just going to clean up the pipe as best as I can & hit it with a rattle can of Chevy gloss black engine paint for now. I have on a line what I think might be a copy of a wheelsmith torque pipe. one of my racing partners has a friend that will build me what ever pipe I would like.

Last edited by Big Maico 393; 03-11-2010 at 07:54 AM.
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